corosys Ready to

corosys Prozeßsysteme und Sensoren GmbH, a German manufacturer of process systems and sensors serving the brewing, beverage, and chemical/pharmaceutical industries, sought to expand into the US brewing market. Entering required a complete redesign of the company's existing control architecture to meet US market regulations and the bespoke compliance standards governing the American brewing and beverage industry. The incumbent automation platform required costly proprietary programming tools and delivered no path to remote maintenance — a growing expectation among US plant operators. Each system deployment consumed four engineering days, constraining corosys's ability to scale a new export operation competitively.

Working with Rockwell Automation, corosys re-engineered its Carbonation System (CCS) on the Integrated Architecture platform. The Allen-Bradley CompactLogix PAC serves as the processing core, running inline CO2 control algorithms that continuously measure carbonation levels at the system outlet and adjust gas flow in real time — eliminating the need for a traditional buffer tank. An Allen-Bradley PanelView HMI handles operator interaction, while PowerFlex 525 and 755 variable-speed drives manage pump control, with full parameters stored directly in the PAC. All components communicate over an EtherNet/IP network built on standard, unmodified Ethernet, enabling straightforward integration into customers' existing enterprise control infrastructure. All hardware arrived pre-certified for the US market, removing compliance risk from the deployment process entirely.

The migration to Rockwell Automation's Integrated Architecture cut per-deployment engineering time from four days to two — a 50% reduction that directly expands corosys's capacity to service US customers at scale. Additional outcomes include:

• Eliminated buffer tank requirement: inline CO2 control removes a major capital equipment constraint for space-limited US breweries
• Remote maintenance deployed in production: EtherNet/IP connectivity enabled live remote diagnostics with a San Diego customer shortly after rollout
• US compliance achieved out of the box: all hardware pre-certified with no state-by-state modifications required
• Simplified maintenance: standardized ladder logic across PAC, drives, and HMI reduces both programming effort and long-term service burden

• Standardizing on a single vendor's integrated platform — controller, drives, HMI, and network — can compress per-deployment engineering time significantly without sacrificing performance.
• EtherNet/IP's standard Ethernet foundation provides a practical, low-cost path to remote monitoring and Connected Enterprise integration.
• For manufacturers entering the US market, selecting hardware that arrives pre-certified eliminates a common compliance bottleneck that can delay customer deployments.
• Inline process control algorithms can replace intermediate buffer equipment, reducing capital cost and floor space requirements — a meaningful differentiator in constrained plant environments.
• Storing drive parameters in the PAC rather than at the device level simplifies commissioning and ongoing maintenance across distributed customer sites.